阅读说明：本技术 用于制备聚合物材料的方法 (Method for producing a polymer material ) 是由 尼古拉斯·迪蒙 盖坦·马奥 于 2020-03-11 设计创作，主要内容包括：本公开涉及用于从干燥编织的预制件来制造产品的方法,所述产品包括由聚合物材料(特别是热塑性的)制成的至少一个区域。通过纬编对应于待获得的成品的形状的连续件以三维生产干燥预制件。随后在模具中通过在压力下加热而固结预制件,并随后将其冷却。根据本发明的方法特别有利,因为所述方法能够获得受控厚度的聚合物材料的部件；所述成品不具有连接部且不需要不同部件的组装。所述方法不会产生材料的任何损失或滴落。根据本发明的方法在环境温度下不伴随任何有毒挥发性元素的释放。(The present disclosure relates to a method for manufacturing a product from a dry woven preform, said product comprising at least one region made of a polymeric material, in particular thermoplastic. The dry preform is produced in three dimensions by weft-knitting a continuous piece corresponding to the shape of the finished product to be obtained. The preform is then consolidated by heating under pressure in a mold and subsequently cooled. The method according to the invention is particularly advantageous because it enables parts of polymeric material to be obtained with a controlled thickness; the finished product has no connections and does not require assembly of different components. The method does not result in any loss or dripping of material. The method according to the invention does not accompany the release of any toxic volatile elements at ambient temperature.)

1. A method for manufacturing a polymer product, wherein the method comprises the steps of:

a) a weft-knitted yarn or set of yarns, wherein the yarn or set of yarns comprises 90% to 100% by volume of a polymeric material;

b) producing the dry preform in a three-dimensional and continuous piece; the preform corresponds to the shape of the finished product to be obtained;

c) consolidating the preform by heating under pressure to reach at least 90% to 100% of the melting point temperature of the polymeric material, and

d) and cooling the finished product.

2. The method according to claim 1, wherein the weft knitting is performed by weaving straight wefts.

3. The method according to any one of claims 1 and 2, wherein at least one region of the final product comprises 95% to 100% by volume of the polymeric material.

4. The method of any preceding claim, wherein the polymeric material is selected from: polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), or combinations thereof.

5. The process according to any of the preceding claims, wherein the dry preform is produced with a density of from 2 to 7 rows/cm, preferably from 3 to 6 rows/cm, and from 2 to 3 columns/cm.

6. The method according to any of the preceding claims, wherein the dry preform has 100g/m²To 1500g/m²Preferably from 500g/m²To 1300g/m²Weight per unit area of (a).

7. A method according to any preceding claim, wherein after step b), the dried preform of polymeric material is deposited on a preform intended to form a composite product, and wherein step c) further comprises allowing the two preforms to consolidate together.

8. The method of any one of claims 1, 2, 3, 4, 5 and 6, wherein after step b), the dry preform of the polymeric material is deposited on a pre-consolidated composite part, and wherein step c) further comprises allowing the dry preform to melt and consolidate or adhere the dry preform and the composite part together.

9. The method of any of the preceding claims, wherein one or more of the yarns includes a filler added to the step of formulating the polymer or spinning the yarn.

10. The method of claim 9, wherein the filler comprises a colored pigment.

11. The method of claim 9, wherein the filler comprises a static dissipative agent.

12. Use of a dry preform obtained by weaving straight weft yarns in 3D for manufacturing a product, wherein the product comprises at least one zone comprising 90% to 100% by volume of a polymeric material.

13. Use of a dry preform obtained by weaving straight weft yarns in 3D to cover a layer of a composite product comprising 90 to 100% by volume of a polymeric material.

14. Use of a dry preform obtained by weaving straight weft yarns in 3D for assembling two different objects.

Technical Field

The present disclosure relates to a method for preparing a polymeric material and manufacturing a product from the polymeric material. The present disclosure relates to the field of products made primarily of polymeric materials. The polymeric material is in particular a thermoplastic material. The invention therefore does not relate, for example, to composite products consisting of a matrix and a reinforcing structure, usually made of fibres. However, the product according to the invention may be combined with a composite product.

Background

According to conventional methods, to obtain a piece of polymeric material, it is necessary to deform a piece of pure polymer (thermoforming), or to inject the polymeric material into a mould (injection).

In thermoforming of thermoplastic materials, the material in the form of a sheet is heated to soften it and shaped using a mold. The material hardens as it cools, thereby retaining that shape.

The disadvantages of this method are: the final shape cannot be too complex, since it must be obtainable by compression moulding; the final thickness of the product depends on the shape and direction of the deformation, meaning that it cannot be adjusted; and the thickness of the original plate depends on the area that experienced the greatest deformation, which results in additional thickness in the area that experienced the lesser deformation.

In injection, complex 3D shapes can be obtained, but the tools to produce these shapes are very expensive.

The disadvantage of this process is that it is not suitable for the production of small or medium-sized series; also, it does not allow the use of continuous fibers.

Drawings

The embodiments are shown by way of example and are not limited by the accompanying figures.

Fig. 1 includes an illustration of a front view of a complex-shaped object that includes a polymeric material.

Fig. 2 includes an illustration of a side view of a complex-shaped object that includes a polymeric material.

Fig. 3 includes an illustration showing a preform comprising a composite component and a component made only of a polymeric material.

Fig. 4 includes a diagram illustrating the finished product obtained from the preform of fig. 3.

Fig. 5 includes an illustration schematically depicting a composite object coated with a layer of polymeric material.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.

Detailed Description

The following discussion will focus on specific implementations and examples of the present teachings. The detailed description is provided to aid in the description of certain embodiments and should not be construed to limit the scope or applicability of the disclosure or teachings. It is to be understood that other embodiments may be used based on the disclosure and teachings provided herein.

The terms "consisting of," "comprising," "including," "containing," "having," "with," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features but may include other features not expressly listed or inherent to such method, article, or apparatus. In addition, "or" refers to an inclusive "or" rather than an exclusive "or" unless explicitly stated otherwise. For example, any of the following conditions a or B may be satisfied: a is true (or present) and B is false (or not present), a is false (or not present) and B is true (or present), and both a and B are true (or present).

Also, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. Unless clearly indicated otherwise, such description should be understood to include one, at least one, or the singular also includes the plural, or vice versa. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for more than one item.

According to specific embodiments, it has been found that the use of yarns, possibly comprising 90 to 100% by volume of polymeric material, or even yarns, possibly comprising only polymeric material, enables the formation of dry preforms in 3D with a technical weaving method. The preform is then fully consolidated by heating.

For the purposes of the embodiments described herein, the term "dry preform" refers to a product obtained by conventionally weaving continuous yarns, in which the yarns form stitches interwoven in a continuous row arrangement.

Producing preforms may typically require a yarn beam for the screen. The different knitting techniques enable to obtain a knit that forms a whole piece of variable local surface mass in a 3D, seamless manner.

Certain weaving techniques allow for circular or straight weaving.

A distinction can be made between weft and warp knitting methods.

The documents US 2016/0075061 a1, US 2017/0157865 a1 and EP 0630735 a2 relate to composite materials comprising a matrix of a polymeric material and a reinforcing structure, the melting point of which is higher than that of the matrix. Typically, the matrix may comprise from 50% to 85% by volume of the final product; the reinforcing structure may comprise from 15% to 50% by volume of the final product. In EP 0630735, the reinforcing structure may, in exemplary embodiments, represent from 50 to 80% in terms of fiber content, while the polymeric material is only 20 to 50%.

According to a particular embodiment, the invention relates to a method of manufacturing a product which may comprise a polymer material. According to some embodiments, the method according to the invention may comprise at least the following steps: weft-knitted yarns or groups of yarns made of 90 to 100% by volume of a polymeric material; producing a dry preform in a three-dimensional and continuous piece, the preform corresponding to the shape of the finished product to be obtained; consolidating the preform by heating under pressure to at least the melting point temperature of the polymeric material; the product thus obtained is cooled.

According to some embodiments, the knitting may be accomplished by a straight knitting method or a circular knitting method.

According to still further embodiments, the preform may advantageously comprise a single, seamless piece of localized surface mass adapted to the desired final thickness.

According to still further embodiments, advantageously, the knitting may be performed by straight knitting, which makes it possible to obtain complex 3D shapes, whereas circular knitting would not do so.

According to particular embodiments, "polymeric material" may refer to a thermoplastic material such as polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), or the like, or combinations thereof.

According to still further embodiments, in particular, the polymeric material may represent from 95% to 100% by volume, or even 100% by volume, in at least one region of the final product.

According to still further embodiments, the dry preform may advantageously be produced at a density of from 2 to 7 rows/cm, preferably from 3 to 6 rows/cm, and from 2 to 3 columns/cm.

According to still other embodiments, advantageously, the dry preform has a mass of 100g/m²To 1500g/m²Preferably from 500g/m²To 1300g/m²Weight per unit area of.

According to certain embodiments, the polymer may include a filler, which may be added at the stage of disposing the polymer or spinning the yarn.

Such fillers may be, for example, colored pigments or static dissipaters according to certain embodiments of the present invention.

According to an alternative embodiment, the preform may constitute a specific non-composite region of the end product, which may comprise another region of composite material. Certain non-composite regions may constitute a surface coating or a layer of polymeric material to assemble two distinct objects.

The invention thus advantageously makes it possible to replace the overmolding process or to form a paint coating or glue layer, or to constitute a surface layer before the application of the final paint.

According to certain embodiments, the preform may be made with colored yarns that put the final color directly into the quality of the finished product without the addition of a paint coating.

According to still further embodiments, the invention may also relate to the use of a dry preform obtained by weaving straight wefts in 3D for manufacturing a product comprising at least one region comprising from 90 to 100% by volume of polymeric material, preferably from 95 to 100% by volume of polymeric material, or even 100% by volume of polymeric material.

The process according to the invention is particularly advantageous because the finished product has a controlled thickness; they have no seams (and thus have aerodynamic profile continuity). This method does not require any assembly of the different components. The method does not result in any loss or dripping of material. The method according to the invention does not accompany the release of any toxic volatile elements at ambient temperature.

Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this description, those skilled in the art will appreciate that those aspects and embodiments are illustrative only and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments listed below.

Embodiment 1. a method for making a polymer product, wherein the method comprises the steps of: a) a weft knitted yarn or set of yarns, wherein the yarn or set of yarns comprises 90% to 100% by volume of a polymeric material;

b) producing the dry preform in a three-dimensional and continuous piece; the preform corresponding to the shape of the finished product to be obtained;

c) consolidating the preform by heating under pressure to reach at least 90% to 100% of the melting point temperature of the polymeric material, and

d) and (6) cooling the finished product.

Embodiment 2. the method according to embodiment 1, wherein the weft knitting is performed by weaving straight wefts.

Embodiment 3. the method of any of embodiments 1 and 2, wherein at least one region of the final product comprises 95% to 100% by volume of the polymeric material.

Embodiment 4. the method of any of the preceding embodiments, wherein the polymeric material is selected from: polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), or combinations thereof.

Embodiment 5. the method according to any of the preceding embodiments, wherein the dried preform is produced with a density of from 2 to 7 rows/cm, preferably from 3 to 6 rows/cm, and from 2 to 3 columns/cm.

Embodiment 6. the method of any of the preceding embodiments, wherein the dried preform has 100g/m²To 1500g/m²Preferably from 500g/m²To 1300g/m²Weight per unit area of (a).

Embodiment 7. the method according to any of the preceding embodiments, wherein after step b), a dry preform of polymeric material is deposited on the preform intended to form the composite product, and wherein step c) further comprises allowing the two preforms to consolidate together.

Embodiment 8. the method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein after step b), a dry preform of polymeric material is deposited on the pre-consolidated composite part, and wherein step c) further comprises allowing the dry preform to melt and consolidate or adhere the dry preform and the composite part together.

Embodiment 9. the method of any of the preceding embodiments, wherein one or more yarns comprise a filler added to the step of formulating the polymer or textile yarn.

Embodiment 10 the method of embodiment 9, wherein the filler comprises a colored pigment.

Embodiment 11 the method of embodiment 9, wherein the filler comprises a static dissipative agent.

Example 12. use of a dry preform obtained by weaving straight weft yarns in 3D for manufacturing a product, wherein the product comprises at least one region comprising 90 to 100% by volume of a polymeric material.

Example 13. use of a dry preform obtained by weaving straight weft yarns in 3D to cover a layer of a composite product comprising 90 to 100% by volume of a polymeric material.

Example 14. use of a dry preform obtained by weaving straight weft yarns in 3D to assemble two different objects.

Embodiment 15. a method for making a polymer product, wherein the method comprises the steps of: a) a weft knitted yarn or set of yarns, wherein the yarn or set of yarns comprises 90% to 100% by volume of a polymeric material; b) producing the dry preform in a three-dimensional and continuous piece; the preform corresponding to the shape of the finished product to be obtained; c) consolidating the preform by heating under pressure to reach at least 90% to 100% of the melting point temperature of the polymeric material, and d) cooling the finished product.

Embodiment 16. the method of embodiment 15, wherein weft knitting is performed by weaving straight picks.

Embodiment 17. the method of embodiment 15, wherein at least one region of the final product comprises 95% to 100% by volume of the polymeric material.

Embodiment 18. the method of embodiment 17, wherein the polymeric material is selected from the group consisting of: polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), or combinations thereof.

Example 19. the method of example 15, wherein the dried preform is produced with a density of from 2 to 7 rows/cm, preferably from 3 to 6 rows/cm, and from 2 to 3 columns/cm.

Example 20 the method of example 15, wherein the dried preform has a g/m of 100²To 1500g/m²Preferably from 500g/m²To 1300g/m²Weight per unit area of (a).

Embodiment 21. the method of embodiment 15, wherein after step b), a dried preform of polymeric material is deposited on the preform intended to form the composite product, and wherein step c) further comprises allowing the two preforms to consolidate together.

Embodiment 22. the method of embodiment 15, wherein after step b), a dry preform of polymeric material is deposited on the pre-consolidated composite part, and wherein step c) further comprises allowing the dry preform to melt and consolidating or adhering the dry preform with the composite part.

Embodiment 23. the method of embodiment 15, wherein the one or more yarns comprise a filler added to the step of formulating the polymer or textile yarn.

Embodiment 24. the method of embodiment 15, wherein the filler comprises a colored pigment.

Embodiment 25. the method of embodiment 15, wherein the filler comprises a static dissipative agent.

Embodiment 26. use of a dry preform obtained by weaving straight weft yarns in 3D for manufacturing a product, wherein the product comprises at least one region comprising 90 to 100% by volume of a polymeric material.

Embodiment 27. the use of embodiment 26, wherein at least one region of the final product comprises 95% to 100% by volume of the polymeric material.

Embodiment 28 the use of embodiment 26, wherein the polymeric material is selected from the group consisting of: polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), or combinations thereof.

Example 29. the use of example 26, wherein the dried preform is produced with a density of from 2 to 7 rows/cm, preferably from 3 to 6 rows/cm, and from 2 to 3 columns/cm.

Embodiment 30. the use of embodiment 26, wherein the dried preform has 100g/m²To 1500g/m²Preferably from 500g/m²To 1300g/m²Weight per unit area of (a).

Example 31. use of a dry preform obtained by weaving straight weft yarns in 3D to cover a layer of a composite product comprising 90 to 100% by volume of a polymeric material.

Embodiment 32. the use of embodiment 31, wherein at least one region of the final product comprises 95% to 100% by volume of the polymeric material.

Embodiment 33. the use of embodiment 31, wherein the polymeric material is selected from: polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), or combinations thereof.

Example 34. the use of example 31, wherein the dried preform is produced with a density of from 2 to 7 rows/cm, preferably from 3 to 6 rows/cm, and from 2 to 3 columns/cm.

Examples of the invention

The concepts described herein will be further described in the following examples, which do not limit the scope of the invention described in the claims.

Example 1: complex and weakly loaded 3D object

The 3D preform is woven into one piece by straight weft knitting. The yarn is made of polycarbonate fibers. The density is 4 rows/cm to 6 rows/cm and 2 columns/cm to 2.8 columns/cm. The weight per unit area is 500g/m²To 1300g/m²。

The 3D preform is placed in a steel mold and a counter-mold (counter-mold) and heated to a temperature of 200 ℃ to 250 ℃ and a pressure of 3 bar to 10 bar.

As shown in fig. 1 (front view) and fig. 2 (side view), the finished product has a young's modulus of 1GPa to 4GPa and a breaking strength of 40MPa to 70MPa in its mechanical properties.

Thanks to the invention, this type of complex-shaped object can be obtained by controlling the thickness. This method consumes less material than conventional thermoforming methods because the thickness of the finished product can be controlled.

Example 2: wing tip type lampshade (Wing tip verine) "

Fig. 3 shows the weaving of a 3D preform into one piece by a straight weft knitting method.

The preform has a region comprising only polycarbonate fibers. The density is 4 rows/cm to 6 rows/cm and 2 columns/cm to 2.8 columns/cm. The weight per unit area in this region was 500g/m²To 1300g/m²。

The same preform comprises another composite region consisting of 20 to 45% by volume of glass fibers and 80 to 55% by volume of polycarbonate. The density is 3.6 to 5 rows/cm and 2 to 2.7 columns/cm. The weight per unit area in this region was 550g/m²To 1800g/m². These two regions form a single knit that is seamless or jointless. These two regions are spread out from each other and are not two superimposed layers.

The 3D preform is placed in a steel mold with a flexible counter mold. All heated to a temperature of 200 ℃ to 250 ℃ and a pressure of 3 bar to 10 bar.

The finished product is shown in fig. 4. The use of a suitable polymer makes the neat polymer transparent after conversion.

The mechanical properties in the pure polymer region are young's modulus from 1GPa to 4GPa and a breaking strength from 40MPa to 70 MPa; and the mechanical properties in the composite region are a Young's modulus of from 4GPa to 19GPa and a fracture strength of from 50MPa to 600 MPa.

In connection with the technique according to the invention, the choice of a suitable polymer makes it possible to obtain both a shape with a desired thickness and a desired transparency.

Example 3: surface layer on composite body

Fig. 5a shows a composite product 1 produced using a first woven 3D preform, using a mixed fiber composed of 33 to 45% by volume of glass fibers and 67 to 55% by volume of polycarbonate.

The density is 3 to 6 rows/cm and 2 to 2.8 columns/cm. The weight per unit area in this region was 600g/m²To 1500g/m². The fibres 2 are present on the surface.

Fig. 5b shows a composite product 1 coated with a polymer layer 3. A second woven 3D preform, a polymer layer 3 obtained with polyurethane fibres is used.

The density is 3 to 6 rows/cm and 2 to 2.7 columns/cm. The weight per unit area in the region is 100g/m²To 200g/m²。

The two preforms are placed together in a rigid mold having a flexible counter mold. All heated to a temperature of 200 ℃ to 215 ℃ and a pressure of 1 bar to 4 bar.

The invention makes it possible to modify the surface layer of a composite object. This is advantageous to facilitate the addition of paint or any other surface treatment. If the neat polymer layer is thick enough, it can completely cover the composite fibers and isolate the composite fibers from the outside.

Depending on the choice of the polymer material, it is possible to load a color pigment thereon and thus create a paint coating. In this case, for example, polycarbonate or PMMA will be chosen as the polymer material.

The invention also makes it possible to charge the polymeric material with static dissipaters, thus giving the finished product an antistatic layer.

Example 4: surface additive layer on composite body

Figure 5a shows a composite product 1 produced according to any of the techniques for producing composite materials.

Fig. 5b shows a composite product 1 coated with a polymer layer 3. The polymer layer 3 is obtained using a woven 3D preform with fibres having a melting temperature lower than the melting temperature of the matrix (e.g. PMMA) of the composite product 1.

The density is 3 to 6 rows/cm and 2 to 2.7 columns/cm. The preform has a weight per unit area of 100g/m2 to 200g/m 2.

The woven preform is overlaid on top of the composite product 1. The 3D preform is placed in a steel mold with a flexible counter mold. All heated to a temperature of 140 ℃ to 190 ℃ and a pressure of 1 bar to 4 bar.

The invention makes it possible to modify the surface layer of a composite object. This is advantageous to facilitate the addition of a protective layer (equivalent to a varnish), a paint, or any other surface treatment. If the neat polymer layer is thick enough, it can completely cover the composite fibers and isolate the composite fibers from the outside.

Depending on the choice of the polymer material, it is possible to load a color pigment thereon and thus create a paint coating. In this case, for example, polycarbonate or PMMA will be chosen as the polymer material.

The invention also makes it possible to charge the polymeric material with static dissipaters, thus giving the finished product an antistatic layer.

The invention is not limited to these examples and other functions may be implemented without departing from the scope of the invention.

It is noted that not all of the activities in the general descriptions or examples above are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Further, the order in which the acts are listed are not necessarily the order in which they are performed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature or feature of any or all the claims.

The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and drawings are not intended to serve as an exhaustive or comprehensive description of all the elements and features of apparatus and systems that utilize the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values expressed as ranges includes each and every value within that range. Many other embodiments will be apparent to the skilled person only after reading this description. Other embodiments may be utilized and derived from the disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the disclosure. The present disclosure is, therefore, to be considered as illustrative and not restrictive.